Sports Ball with Integral Ball Casing and Bladder Body

ABSTRACT

A sports ball includes a barebone ball and an outer ball layer. The barebone ball includes an inflatable bladder body and a ball casing. The ball casing, which is formed in an integrated structure, has an outer circumferential surface, an inner circumferential surface to define an interior cavity to fittingly enclose the bladder body therein, and a plurality of pre-formed channels integrally and indently formed on the outer circumferential surface, such that the ball casing and the bladder body enclosed therewithin form a one piece integrated semi-product of the sports ball. The outer ball layer comprising a plurality of outer cover panels overlapping on the outer circumferential surface of the ball casing at a position that edges of each of the outer cover panels are aligned with the corresponding pre-formed channels respectively.

CROSS REFERENCE OF RELATED APPLICATION

This is a divisional application that claims the benefit of priorityunder 35 U.S.C. §119 to a non-provisional application, application Ser.No. 12/070,557, filed Feb. 19, 2008.

BACKGROUND OF THE PRESENT INVENTION

1. Field of Invention

The present invention relates to a ball, and more particularly to asports ball comprising a barebone ball having an integral structure foroptimizing a structural strength of the sports ball.

2. Description of Related Arts

A conventional sports ball, such as a conventional soccer ball, usuallycomprises a ball bladder, an inner lining, and a ball carcass. The ballcarcass comprises a plurality of carcass panels attached on the ballbladder, wherein each of the carcass panels is usually stitched toadjacent carcass panels for forming a substantially round sports ball.Traditionally, much has been done in the development of the ball bladderand intermediate construction between the ball bladder and the ballcarcass.

However, there are also several disadvantages for this kind oftraditional sports ball. For example, the carcass panels, being attachedonto the ball bladder, involve expensive and time-consumingmanufacturing procedures, yet the resulting sports ball may not have theoptimal roundness. One particularly-pressing problem for conventionalstitched sports ball is that the carcass panels cannot have too sharp ashape for it is difficult for sharp corners to be adequately stitchedwith adjacent carcass panels.

As a result, sports balls having a stitch-less structure have beendeveloped to overcome the many conventional deep-seated problems presentin stitched sports ball. For example, U.S. Pat. No. 6,685,585 toHiroshima et al. discloses a ball for a ball game comprising an elasticbladder, a reinforced layer, and a plurality of leather panels. Morespecifically, each of the leather panels is bonded onto the reinforcedlayer, wherein a peripheral edge portion of each leather panels isfolded toward an inside. A thickness adjusting member is disposed in avoid defined by the folded peripheral portions and bonded onto a back ofeach leather panel. Although this sports ball does not involve stitchingon the leather panels, thereby substantially overcoming thedisadvantages associated with stitching, it has several otherdisadvantages.

First, the Hiroshima's patent specifically discloses a bonding techniquethereby each of the leather panels is inwardly folded at thecorresponding peripheral portion to bond with the thickness adjustingmember. Thus, the Hiroshima's patent discloses a state of art where eachthe leather panels has two portions, a main portion which is above thethickness adjusting member, and a peripheral portion which is bonded atside portions of the corresponding thickness adjusting member. Now, theproblem with this construction is that while the main portion of each ofthe leather panels is elastically supported by the thickness adjustingmember, the corresponding peripheral portion does not. As a result, thesports ball suffers from non-uniform cushion effect because of thebonding technique of the leather panels. When a user of that inventionkicks on the main portion of the leather panel, he will enjoysubstantial cushioning effect from the thickness adjusting member.However, when the user kicks on the peripheral portion of the leatherpanel, he will cease to enjoy the same amount of cushioning effect as ifhe kicks on the main portion.

Second, it is reasonably clear that in order to manufacture the ballstated in the Hiroshima's patent, one must take substantial amount oftime for precise and effective attachment between the thicknessadjusting member and the leather panels. In other words, the balldisclosed in the Hiroshima's patent requires expensive manufacturingcost. Moreover, since the manufacturing procedures are time-consuming,when the balls are needed in large quantity, such as when the inventorsor their assignees or the licensors need to meet substantial marketdemand, there is little chance that they could produce the balls inlarge quantity in a relatively short period of time. This is extremelyimportant because major soccer events, such as World Cup, are only heldonce in a few years.

Another problem for traditional sports balls is that no matter how goodthe stitching and/or the construction of leather panels, the ballbladder and the ball carcass are inherently two different components.The ball carcass may be attached onto the ball bladder with an innerlining in between, the attachment may not be good enough so that thesports ball may have a reduced span of life.

SUMMARY OF THE PRESENT INVENTION

A main object of the present invention is to provide a sports ballcomprising a barebone ball having an integral structure for optimizing astructural strength of the sports ball.

Another object of the present invention is to provide a sports ballcomprising an inflatable bladder body, and a ball casing integrallyformed with the inflatable bladder body so as to completely overcome theinsecure attachment disadvantage for conventional sports ball.

Another object of the present invention is to provide a sports ballcomprising a barebone ball, wherein the sports ball can be manufacturedinto a wide variety of ball types, so as to facilitate widespreadapplications of the present invention. For example, the sports ball canbe manufactured as a soccer ball, an America football, or even a volleyball with even cushioning throughout the entire sports ball.

Another object of the present invention is to provide a method ofmanufacturing a sports ball comprising a barebone ball having anintegral structure for optimizing a structural strength of the sportsball.

Another object of the present invention is to provide a method ofmanufacturing a sports ball, wherein the method reduces the number ofsteps for manufacturing a traditional sports ball so as to minimize themanufacturing cost of a sports ball.

Accordingly, in order to accomplish the above objects, the presentinvention provides a sports ball, comprising:

-   -   a barebone ball, which comprises    -   an inflatable bladder body; and    -   a ball casing, which is formed in an integrated structure,        having an outer circumferential surface, an inner        circumferential surface to define an interior cavity to        fittingly enclose the bladder body therein, and a plurality of        pre-formed channels integrally and indently formed on the outer        circumferential surface, such that the ball casing and the        bladder body enclosed therewithin form a one piece integrated        semi-product of the sports ball; and    -   an outer ball layer comprising a plurality of outer cover panels        overlappedly attached on the outer circumferential surface of        the ball casing at a position that edges of each of the outer        cover panels are aligned with the corresponding pre-formed        channels respectively.

Moreover, the present invention also provides a method of manufacturinga sports ball, comprising the steps of:

-   -   (a) providing an inflatable bladder body and a ball casing        having a shape corresponding to the bladder body after being        inflated;    -   (b) placing the bladder body and the ball casing in a casing        mold at a position that the bladder body is enclosed within the        ball casing;    -   (c) vulcanizing the ball casing with heat to integrally bond the        ball bladder with the ball casing to form a one piece integrated        barebone ball as a semi-product of the sports ball, wherein a        plurality of pre-formed channels are integrally and indently        formed on an outer circumferential surface of the ball casing;        and    -   (d) overlappedly attaching a plurality of outer cover panels on        the outer circumferential surface of the ball casing at a        position that edges of each of the outer cover panels are        aligned with the corresponding pre-formed channels respectively        to form an outer ball layer to enclose the ball casing.

These and other objectives, features, and advantages of the presentinvention will become apparent from the following detailed description,the accompanying drawings, and the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A to FIG. 1D is schematic diagrams of a method of manufacturing asports ball according to a preferred embodiment of the presentinvention.

FIG. 2 is a perspective view of a sports ball according to a preferredembodiment of the present invention.

FIG. 3 is a perspective view of the inflatable bladder body of thesports ball according to the above preferred embodiment of the presentinvention.

FIG. 4 is a sectional side view of the sports ball according to theabove preferred embodiment of the present invention.

FIG. 5 is a perspective view of an alternative mode of the sports ballaccording to the above preferred embodiment of the present invention.

FIG. 6 is a perspective view of the alternative mode of the inflatablebladder body of the sports ball according to the above preferredembodiment of the present invention.

FIG. 7 is a sectional side view of the alternative mode of the sportsball according to the above preferred embodiment of the presentinvention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring to FIG. 1A, FIG. 1C, FIG. 1D, and FIG. 2 to FIG. 4 of thedrawings, a method of manufacturing a sports ball according to thepreferred embodiment of the present invention is illustrated, in whichthe method comprises the steps of:

-   -   (a) providing an inflatable bladder body 11 and a ball casing 12        having a shape corresponding to the bladder body 11 after being        inflated;    -   (b) placing the bladder body 11 and the ball casing 12 in a        casing mold 70 at a position that the bladder body 11 is        enclosed within the ball casing 12;    -   (c) vulcanizing the ball casing 12 with heat to integrally bond        the bladder body 11 with the ball casing 12 to form a one piece        integrated barebone ball 10 as a semi-product of the sports        ball, wherein a plurality of pre-formed channels 124 are        integrally and indently formed on an outer circumferential        surface 121 of the ball casing 12; and    -   (d) overlappedly attaching a plurality of outer cover panels 21        on the outer circumferential surface 121 of the ball casing 12        at a position that edges of each of the outer cover panels 21        are aligned with the corresponding pre-formed channels 124        respectively to form an outer ball layer to enclose the ball        casing 12.

Step (b) further comprises a step of aligning two or more casing panels126 edge-to-edge to form the ball casing 12 such that the casing panels126 are aligned to enclose the bladder body 11 in the casing mold 70.

In step (c), the casing mold 70 comprises a plurality of channelprotrusions 71 integrally protruded from an inner mold surface to pressagainst the outer circumferential surface 121 of the ball casing 12during vulcanization. Each of the channel protrusions 71 has two slantedpressing surfaces 711 such that each of the per-formed channels 124 isformed to have two slanted sidewalls 1241 indented on the outercircumferential surface 121 of the ball casing 12 during vulcanization,so that edge portions of the two neighboring outer cover panels 21 areoverlappedly attached on the slanted sidewalls 1241 of the correspondingpre-formed channel 124 respectively so as to be securely and fittedlyattached onto the barebone ball 10.

In step (d), the outer cover panels 21 are securely and fittedly adheredon the outer circumferential surface 121 of the ball casing 12 of thebarebone ball 10.

According to the preferred embodiment of the present invention, theouter circumferential surface of the bladder body 11 is integrated withthe inner circumferential surface 122 of the ball casing 12 to form theone piece integrated barebone ball 10 after vulcanization. The ballcasing 12 is made of rubber material for providing a cushion effect atany point of the barebone ball 10 after vulcanization.

It is worth mentioning that the sports ball of the present invention canbe manufactured as a soccer ball, a volley ball or even an Americafootball. Preferably, the soccer ball is made by the above mentionedstructure and its manufacturing process thereof.

Referring to FIG. 2 to FIG. 4 of the drawings, a sports ball accordingto a preferred embodiment of the present invention is illustrated, inwhich the sports ball comprises a barebone ball 10 and an outer balllayer 20. Accordingly, the sports ball of the present invention isillustrated as a soccer ball.

The barebone ball 10 comprises an inflatable bladder body 11 and a ballcasing 12. The ball casing 12, which is formed in an one-pieceintegrated structure, has an outer circumferential surface 121, an innercircumferential surface 122 to define an interior cavity 123 tofittingly enclose the bladder body 11 therein, and a plurality ofpre-formed channels 124 integrally and indently formed on the outercircumferential surface 121, such that the ball casing 12 and thebladder body 11 enclosed therewithin form a one piece integratedsemi-product of the sports ball.

On the other hand, the outer ball layer 20 comprises a plurality ofouter cover panels 21 overlappedly attaching on the outercircumferential surface 121 of the ball casing 12 at a position thatedges of each of the outer cover panels 21 are aligned with thecorresponding pre-formed channels 124 respectively so as to fittedlyattach onto the ball casing 12.

According to the preferred embodiment of the present invention, each ofthe per-formed channels 124 has two slanted sidewalls 1241 indented onthe outer circumferential surface 121 of the ball casing 12 such thatedge portions of the two neighboring outer cover panels 21 areoverlappedly attached on the sidewalls 1241 of the correspondingpre-formed channel 124 respectively such that each of the outer coverpanels 21 are adapted to be fittedly attached onto the outercircumferential surface 121 along the corresponding pre-formed channels124.

It is worth mentioning that an outer circumferential surface 114 of thebladder body 11 is integrated with the inner circumferential surface 122of the ball casing 12 after the ball casing 12 is heat-treated to formthe one piece integrated semi-product of the sports ball. As a result,the ball casing 12 and the bladder body 11 is integrated as a one-piecebody so as to possess the optimal roundness of the ball casing 12 andthe structural integrity and strength of the semi-product of the sportsball. Moreover, the ball casing 12 is made of rubber or other softmaterials (such as PVC, foaming materials etc.) for providing a cushioneffect at any point of the barebone ball 10. Since the ball casing 12 isformed as a one-piece semi-product without involving stitching or anyother mechanical connection mechanisms, the ball casing 12 is capable ofpossessing a truly rounded outer shape with optimally even cushioningeffect and maximal structural integrity and strength. In other words,the present invention resolves the problem of inadequate roundness andweak structural integrity of conventional sports ball. Moreover, theouter cover panels 21 are adhered on the outer circumferential surface121 of the ball casing 12 of the barebone ball 10.

It is worth mentioning that the barebone ball 10 can also be consideredas a final product of the sports ball without the outer ball layer 20,wherein the ball casing 12 of the barebone ball 10 can be considered asthe carcass panels of the sports ball. Moreover, it is worth mentioningthat the channels 124 pre-formed on the barebone ball 10 can also beused as a water repellent guiding channels when the sports ball of thepresent invention is played in a wet condition, such as in a rainingday.

As shown in FIG. 3 of the drawings, the inflatable bladder body 11comprises an inflatable bladder 111 for being popped by air inflationand an exterior web layer 112, which is integrally attached on an outersurface of the inflatable bladder 111, and comprises at least anelongated strengthened thread 113 evenly wound around the outer surfaceof the inflatable bladder 111 such that the web layer 112 embraces theinflatable bladder 111 for resisting stress and impact force applied tothe inflatable bladder 111.

In other words, the inflatable bladder body 10, which is disposed insidethe ball casing 12, comprises a rubber made inflatable bladder 111 and avalve stem 114 mounted thereon wherein the ball casing 12 has a valvehole 125 formed thereon for aligning with the valve stem 114. Theinflatable bladder body 10 comprises an exterior web layer 112integrally attached on an outer surface of the inflatable bladder 111.

In order to enable the strengthened threads 113 being permanentlyaffixed on the outer surface of the inflatable bladder 111, beforewinding onto the inflatable bladder 111, the strengthened threads 113are coated with glue for adhering onto the outer surface of theinflatable bladder 111 and each other. Moreover, the inflatable bladder111 with the adhering strengthened threads 113 thereon are togethercured by heating in a mold, so that the adhering strengthened threads113 will be hardened to form the exterior web layer 112 which ispermanently united with the inflatable bladder 111 integrally.

As an alternative mode shown in FIG. 1B, and FIG. 5 to FIG. 7 of thedrawings, the barebone ball 10′ comprises an inflatable bladder body 11′and a ball casing 12′. The ball casing 12′, which is formed in aone-piece integrated structure, has an outer circumferential surface121′, an inner circumferential surface 122′ to define an interior cavity123′ to fittingly enclose the bladder body 11′ therein, and a pluralityof pre-formed channels 124′ integrally and indently formed on the outercircumferential surface 121′, such that the ball casing 12′ and thebladder body 11′ enclosed therewithin form a one piece integratedsemi-product of the sports ball.

On the other hand, the outer ball layer 20′ comprises a plurality ofouter cover panels 21′ overlappedly attaching on the outercircumferential surface 121′ of the ball casing 12′ at a position thatedges of each of the outer cover panels 21′ are aligned with thecorresponding pre-formed channels 124′ respectively so as to fittedlyattach onto the ball casing 12′.

Moreover, the bladder body 11′ comprises an inflatable bladder 111′ forbeing popped by air inflation and a construction ball pocket 112′, whichis made of fabric material and constructed to have a true roundnessshape, having an interior receiving cavity defined therein to sealedlyreceive the inflatable bladder 111′, such that the construction ballpocket 112′ is arranged to retain a true roundness shape of theinflatable bladder 111′ after the inflatable bladder 111′ is inflated.According to the preferred embodiment, the inflatable bladder 111′ ismade of rubber or the like that is capable of being inflated with acompression air at a predetermined pressure for popping up andsupporting the ball casing 12′.

The construction ball pocket 112′ comprises a plurality of ball pocketleaves 1121′ integrally connected with each other. Practically, thefabric made construction ball pocket 112′ is able to form a sphericalbody that the construction ball pocket 112′ is constructed to have atrue roundness shape so as to retain a maximum diameter of theinflatable bladder 111′ after it is inflated.

The construction ball pocket 112′ is preferred to be made of fabricmaterial having a durability, stretchability and adhesiveablility.Preferably, the construction ball pocket 112′ can be made of a mixturefabric mixed with cotton and polyester because the cotton has a goodstretchability and is able to absorb adhesive material and the polyesteris durable and has a strong strength that is able to resist strain whenthe inflatable bladder 111′ is inflated.

The inflatable bladder 111′ is disposed in the construction ball pocket112′ which has a size slightly bigger than the inflatable bladder 111′in such a manner that when the inflatable bladder 111′ is inflated, anouter spherical surface of the inflatable bladder 111′ is preferred tobe slightly spaced apart from an inner spherical surface of theconstruction ball pocket 112′ to form an air cushion layer therebetween.The air cushion layer is adapted for providing a cushion effect for thesports ball to provide softness for the sports ball and tolerate heavierimpact thereon.

It is worth mentioning that the barebone ball 10 may further an innerlining layer integrally formed between the ball casing 12 and theinflatable bladder body 11 for further reinforcing a strength of thebarebone ball 10.

One skilled in the art will understand that the embodiment of thepresent invention as shown in the drawings and described above isexemplary only and not intended to be limiting.

It will thus be seen that the objects of the present invention have beenfully and effectively accomplished. The embodiments have been shown anddescribed for the purposes of illustrating the functional and structuralprinciples of the present invention and is subject to change withoutdeparture from such principles. Therefore, this invention includes allmodifications encompassed within the spirit and scope of the followingclaims.

What is claimed is:
 1. A method of manufacturing a sports ball,comprising the steps of: (a) providing an inflatable bladder body and aball casing having a shape corresponding to said bladder body afterbeing inflated; (b) placing said bladder body and said ball casing in acasing mold at a position that said bladder body is enclosed within saidball casing; (c) vulcanizing said ball casing with heat to integrallybond said ball bladder with said ball casing to form a one pieceintegrated barebone ball as a semi-product of said sports ball, whereina plurality of pre-formed channels are integrally and indently formed onan outer circumferential surface of said ball casing; and (d)overlappedly attaching a plurality of outer cover panels on said outercircumferential surface of said ball casing at a position that edges ofeach of said outer cover panels are aligned with said correspondingpre-formed channels respectively to form an outer ball layer to enclosesaid ball casing.
 2. The method, as recited in claim 1, wherein the step(b) further comprises a step of aligning two or more casing panelsedge-to-edge to form said ball casing such that said casing panels arealigned to enclose said bladder body in said casing mold.
 3. The methodas recited in claim 1, wherein, in the step (c), said casing moldcomprises a plurality of channel protrusions integrally protruded froman inner mold surface to press against said outer circumferentialsurface of said ball casing during vulcanization.
 4. The method asrecited in claim 2, wherein, in the step (c), said casing mold comprisesa plurality of channel protrusions integrally protruded from an innermold surface to press against said outer circumferential surface of saidball casing during vulcanization.
 5. The method, as recited in claim 3,wherein each of said channel protrusions has two slanted pressingsurfaces that each of said per-formed channels is formed to have twoslanted sidewalls indented on said outer circumferential surface of saidball casing during vulcanization, so that edge portions of said twoneighboring outer cover panels are overlappedly attached on saidsidewalls of said corresponding pre-formed channel respectively.
 6. Themethod, as recited in claim 4, wherein each of said channel protrusionshas two slanted pressing surfaces that each of said per-formed channelsis formed to have two slanted sidewalls indented on said outercircumferential surface of said ball casing during vulcanization, sothat edge portions of said two neighboring outer cover panels areoverlappedly attached on said sidewalls of said corresponding pre-formedchannel respectively.
 7. The method, as recited in claim 1, wherein anouter circumferential surface of said bladder body is integrated withsaid inner circumferential surface of said ball casing to form said onepiece integrated barebone ball after vulcanization.
 8. The method, asrecited in claim 2, wherein an outer circumferential surface of saidbladder body is integrated with said inner circumferential surface ofsaid ball casing to form said one piece integrated barebone ball aftervulcanization.
 9. The method, as recited in claim 5, wherein an outercircumferential surface of said bladder body is integrated with saidinner circumferential surface of said ball casing to form said one pieceintegrated barebone ball after vulcanization.
 10. The method, as recitedin claim 6, wherein an outer circumferential surface of said bladderbody is integrated with said inner circumferential surface of said ballcasing to form said one piece integrated barebone ball aftervulcanization.
 11. The method, as recited in claim 1, wherein said ballcasing is made of rubber material for providing a cushion effect at anypoint of said barebone ball after vulcanization.
 12. The method, asrecited in claim 2, wherein said ball casing is made of rubber materialfor providing a cushion effect at any point of said barebone ball aftervulcanization.
 13. The method, as recited in claim 9, wherein said ballcasing is made of rubber material for providing a cushion effect at anypoint of said barebone ball after vulcanization.
 14. The method, asrecited in claim 10, wherein said ball casing is made of rubber materialfor providing a cushion effect at any point of said barebone ball aftervulcanization.
 15. The method as recited in claim 1, wherein, in thestep (d), said outer cover panels are adhered on said outercircumferential surface of said ball casing of said barebone ball. 16.The method as recited in claim 2, wherein, in the step (d), said outercover panels are adhered on said outer circumferential surface of saidball casing of said barebone ball.
 17. The method as recited in claim 9,wherein, in the step (d), said outer cover panels are adhered on saidouter circumferential surface of said ball casing of said barebone ball.18. The method as recited in claim 10, wherein, in the step (d), saidouter cover panels are adhered on said outer circumferential surface ofsaid ball casing of said barebone ball.
 19. The method as recited inclaim 13, wherein, in the step (d), said outer cover panels are adheredon said outer circumferential surface of said ball casing of saidbarebone ball.
 20. The method as recited in claim 14, wherein, in thestep (d), said outer cover panels are adhered on said outercircumferential surface of said ball casing of said barebone ball.